EP4079520A1 - Composition de résine pour encapsulation de cellule solaire, matériau d'encapsulation de cellule solaire ainsi que procédé de fabrication de celui-ci, et module de cellules solaires - Google Patents

Composition de résine pour encapsulation de cellule solaire, matériau d'encapsulation de cellule solaire ainsi que procédé de fabrication de celui-ci, et module de cellules solaires Download PDF

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Publication number
EP4079520A1
EP4079520A1 EP20900900.0A EP20900900A EP4079520A1 EP 4079520 A1 EP4079520 A1 EP 4079520A1 EP 20900900 A EP20900900 A EP 20900900A EP 4079520 A1 EP4079520 A1 EP 4079520A1
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EP
European Patent Office
Prior art keywords
solar cell
ethylene
copolymer
resin composition
mass
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20900900.0A
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German (de)
English (en)
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EP4079520A4 (fr
Inventor
Kei NAGAYAMA
Kana KUKITA
Motoaki Isokawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dow Mitsui Polychemicals Co Ltd
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Dow Mitsui Polychemicals Co Ltd
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Application filed by Dow Mitsui Polychemicals Co Ltd filed Critical Dow Mitsui Polychemicals Co Ltd
Publication of EP4079520A1 publication Critical patent/EP4079520A1/fr
Publication of EP4079520A4 publication Critical patent/EP4079520A4/fr
Pending legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
    • C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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    • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
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    • C08F218/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid
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    • C08F218/04—Vinyl esters
    • C08F218/08—Vinyl acetate
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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    • C08F220/32—Esters containing oxygen in addition to the carboxy oxygen containing epoxy radicals
    • C08F220/325—Esters containing oxygen in addition to the carboxy oxygen containing epoxy radicals containing glycidyl radical, e.g. glycidyl (meth)acrylate
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F230/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal
    • C08F230/04—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal
    • C08F230/08—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal containing silicon
    • C08F230/085—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal containing silicon the monomer being a polymerisable silane, e.g. (meth)acryloyloxy trialkoxy silanes or vinyl trialkoxysilanes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/22—Compounds containing nitrogen bound to another nitrogen atom
    • C08K5/24—Derivatives of hydrazine
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
    • C08K5/3472—Five-membered rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L23/08—Copolymers of ethene
    • C—CHEMISTRY; METALLURGY
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Definitions

  • the present invention relates to a resin composition for a solar cell encapsulant, a solar cell encapsulant, a manufacturing method of a solar cell encapsulant, and a solar cell module.
  • Photovoltaic power generation directly converts solar energy into electrical energy using a semiconductor (solar cell element) such as a silicon cell.
  • a semiconductor solar cell element
  • the solar cell element is sandwiched between encapsulants to protect the solar cell element and to prevent the incorporation of a foreign matter or the intrusion of moisture or the like into the solar cell element.
  • the solar cell element usually has a metal electrode for collecting electric charges that are obtained by photovoltaic power and is usually configured by connecting a plurality of cells for a solar cell with metal wiring in order to obtain a high electric output.
  • a metal electrode for collecting electric charges that are obtained by photovoltaic power
  • the yellowing of these solar cell encapsulants reduces the amount of light received by the solar cell element. Therefore, the yellowing of the solar cell encapsulants causes a decrease in the power generation efficiency of solar cell modules, and a solar cell encapsulant capable of effectively preventing yellowing is desired.
  • Examples of techniques for suppressing such yellowing of solar cell encapsulants include techniques described in Patent Document 1 ( Japanese Unexamined Patent Publication No. 2014-107323 ) and Patent Document 2 ( Japanese Unexamined Patent Publication No. 2018-174202 ) .
  • Patent Document 1 discloses an encapsulating film for a solar cell containing an ethylene-based copolymer, a pigment, and a metal inactivating agent, in which the metal inactivating agent contains at least one kind of compound selected from the group consisting of a triazole-based compound, a benzotriazole-based compound, and a hydrazine compound. Patent Document 1 describes that such an encapsulating film for a solar cell is capable of suppressing the occurrence of yellowing.
  • Patent Document 2 discloses an encapsulant for a solar cell containing an ethylene-polar monomer copolymer, a cross-linking agent, an ultraviolet absorber, and a carbodiimide compound, in which the cross-linking agent has a specific structure, the ultraviolet absorber is a benzotriazole-based ultraviolet absorber, and the carbodiimide compound is a cyclic carbodiimide compound having a specific structure.
  • Patent Document 2 describes that such an encapsulant for a solar cell is capable of maintaining an acid trapping function for a long period of time even in a high temperature and high humidity environment and in an environment exposed to ultraviolet rays for a long period of time, suppresses yellowing, and is highly transparent and excellent in terms of the cross-linking efficiency.
  • a demand for suppressing the yellowing of solar cell encapsulants is growing more intense.
  • the present invention has been made in view of the above-described circumstances and provides a solar cell encapsulant having improved yellowing resistance.
  • the present inventors repeated intensive studies to solve the above-described problems. As a result, the present inventors found that it is possible to improve the yellowing resistance of a solar cell encapsulant that is obtained, by combining at least one kind of ethylene-polar monomer copolymer selected from an ethylene-vinyl ester copolymer and an ethylene-unsaturated carboxylic acid ester copolymer, an epoxy group-containing ethylene-based copolymer, an ethylene- ⁇ -olefin copolymer, and a metal inactivating agent and reached the present invention.
  • ethylene-polar monomer copolymer selected from an ethylene-vinyl ester copolymer and an ethylene-unsaturated carboxylic acid ester copolymer, an epoxy group-containing ethylene-based copolymer, an ethylene- ⁇ -olefin copolymer, and a metal inactivating agent and reached the present invention.
  • a resin composition for a solar cell encapsulant, a solar cell encapsulant, a manufacturing method of a solar cell encapsulant, and a solar cell module which will be described below, are provided.
  • Fig. 1 is a cross-sectional view schematically illustrating an example of the structure of a solar cell module of an embodiment according to the present invention.
  • (meth)acryl means acryl or methacryl.
  • a resin composition for a solar cell encapsulant according to the present embodiment is a resin composition which is used for forming a solar cell encapsulant, the resin composition containing at least one kind of ethylene-polar monomer copolymer (A1) selected from an ethylene-vinyl ester copolymer and an ethylene-unsaturated carboxylic acid ester copolymer, an epoxy group-containing ethylene-based copolymer (A2) (excluding the ethylene-polar monomer copolymer (A1)), an ethylene- ⁇ -olefin copolymer (B), and a metal inactivating agent (C).
  • A1 ethylene-polar monomer copolymer
  • A2 epoxy group-containing ethylene-based copolymer
  • B ethylene- ⁇ -olefin copolymer
  • C metal inactivating agent
  • the resin composition (P) contains the ethylene-polar monomer copolymer (A1), the epoxy group-containing ethylene-based copolymer (A2), the ethylene- ⁇ -olefin copolymer (B), and the metal inactivating agent (C) and is thus capable of improving the yellowing resistance of a solar cell encapsulant to be obtained.
  • the epoxy group-containing ethylene-based copolymer (A2) and a functional group of the metal inactivating agent (C) interact or react with each other, which makes it easier for a metal ion to be coordinated to the metal inactivating agent (C) and thus suppresses the promotion of deterioration of a resin due to the metal ion.
  • the use of the resin composition for a solar cell encapsulant according to the present embodiment enables the obtainment of a solar cell encapsulant having improved yellowing resistance.
  • the total content of the ethylene-polar monomer copolymer (A1), the epoxy group-containing ethylene-based copolymer (A2), and the ethylene- ⁇ -olefin copolymer (B) is preferably equal to or more than 60% by mass, more preferably equal to or more than 70% by mass, even more preferably equal to or more than 80% by mass, far even more preferably equal to or more than 90% by mass, and particularly preferably equal to or more than 95% by mass.
  • the total content of the ethylene-polar monomer copolymer (A1), the epoxy group-containing ethylene-based copolymer (A2), and the ethylene- ⁇ -olefin copolymer (B) is within the above-described range, it is possible to further improve the balance of the transparency, interlayer adhesiveness, insulating properties, rigidity, water resistance, flexibility, mechanical properties, heat resistance, handleability, and processability of solar cell encapsulants to be obtained and the PID resistance and the like of solar cell modules to be obtained.
  • the ethylene-polar monomer copolymer (A1) contains one or more kinds selected from an ethylene-vinyl ester copolymer and an ethylene-unsaturated carboxylic acid ester copolymer.
  • ethylene-vinyl ester copolymer it is possible to use one or more kinds selected from an ethylene-vinyl acetate copolymer, an ethylene-vinyl propionate copolymer, an ethylene-vinyl butyrate copolymer, an ethylene-vinyl stearate copolymer and the like.
  • the ethylene-unsaturated carboxylic acid ester copolymer according to the present embodiment is a polymer obtained by copolymerizing ethylene and at least one kind of unsaturated carboxylic acid ester.
  • a copolymer made up of ethylene and an alkyl ester of an unsaturated carboxylic acid can be exemplified.
  • Examples of an unsaturated carboxylic acid in the unsaturated carboxylic acid ester include acrylic acid, methacrylic acid, ethacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, itaconic acid, itaconic anhydride, and the like.
  • Examples of an alkyl moiety in the alkyl ester of the unsaturated carboxylic acid include alkyl groups having 1 to 12 carbon atoms, and more specifically, alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, secondary butyl, 2-ethylhexyl, and isooctyl can be exemplified.
  • the number of carbon atoms in the alkyl moiety of the alkyl ester is preferably 1 to 8.
  • unsaturated carboxylic acid ester one or more kinds selected from (meth) acrylic acid esters such as methyl (meth) acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, n-propyl (meth)acrylate, isobutyl (meth)acrylate, n-butyl (meth)acrylate, isooctyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate are preferably contained.
  • These unsaturated carboxylic acid esters may be used singly or two or more kinds thereof may be used in combination.
  • one or more kinds selected from methyl (meth) acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, n-propyl (meth)acrylate, isobutyl (meth)acrylate, and n-butyl (meth)acrylate are more preferably contained.
  • the ethylene-unsaturated carboxylic acid ester copolymer is preferably an ethylene-(meth)acrylic acid ester copolymer.
  • a copolymer containing one kind of compound as the (meth)acrylic acid ester is preferable.
  • Examples of such a copolymer include an ethylene-methyl (meth)acrylate copolymer, an ethylene-ethyl (meth)acrylate copolymer, an ethylene-isopropyl (meth)acrylate copolymer, an ethylene-n-propyl (meth)acrylate copolymer, an ethylene-isobutyl (meth)acrylate copolymer, an ethylene-n-butyl (meth)acrylate copolymer, an ethylene-isooctyl (meth)acrylate copolymer, an ethylene-2-ethylhexyl (meth)acrylate copolymer, and the like.
  • the ethylene-polar monomer copolymer (A1) preferably contains one or more kinds selected from an ethylene-vinyl acetate copolymer, an ethylene-methyl (meth)acrylate copolymer, an ethylene-ethyl (meth)acrylate copolymer, an ethylene-isopropyl (meth)acrylate copolymer, an ethylene-n-propyl (meth)acrylate copolymer, an ethylene-isobutyl (meth) acrylate copolymer, and an ethylene-n-butyl (meth)acrylate copolymer and more preferably contains an ethylene-vinyl acetate copolymer.
  • the ethylene-polar monomer copolymer (A1) may be used singly or two or more kinds may be used in combination.
  • the content of a polar monomer in the ethylene-polar monomer copolymer (A1) is preferably equal to or more than 5% by mass and equal to or less than 50% by mass, more preferably equal to or more than 8% by mass and equal to or less than 45% by mass, and particularly preferably equal to or more than 8% by mass and equal to or less than 30% by mass.
  • the content of the polar monomer can be measured according to, for example, JIS K7192: 1999.
  • the content of the polar monomer is measured from, for example, the infrared absorption spectrum (IR) attributable to the unsaturated carboxylic acid ester.
  • IR infrared absorption spectrum
  • the unsaturated carboxylic acid ester is ethyl acrylate (EA)
  • the content of the polar monomer is obtained from the absorbance at 860 cm -1 attributable to EA.
  • the calibration curve is obtained from the correlation between the EA concentration obtained from the nuclear magnetic resonance spectrum (NMR) and the absorbance at 860 cm -1 of IR.
  • the melt mass flow rate (MFR) of the ethylene-polar monomer copolymer (A1) as measured according to JIS K 7210: 1999 under conditions of 190°C and a load of 2160 g is preferably equal to or more than 0.1 g/10 minutes and equal to or less than 300 g/10 minutes, more preferably equal to or more than 0.2 g/10 minutes and equal to or less than 200 g/10 minutes, even more preferably equal to or more than 0.5 g/10 minutes and equal to or less than 180 g/10 minutes, and particularly preferably equal to or more than 1.0 g/10 minutes and equal to or less than 30 g/10 minutes.
  • the MFR of the ethylene-polar monomer copolymer (A1) may be adjusted by blending a plurality of ethylene-polar monomer copolymers (A1) having different MFRs.
  • a manufacturing method of the ethylene-polar monomer copolymer in the ethylene-polar monomer copolymer (A1) according to the present embodiment is not particularly limited, and the ethylene-polar monomer copolymer can be produced by a known method.
  • the ethylene-polar monomer copolymer can be obtained by the radical copolymerization of the individual polymerization components at a high temperature and a high pressure.
  • a commercially available product may be used as the ethylene-polar monomer copolymer in the ethylene-polar monomer copolymer (A1).
  • At least a part of the ethylene-polar monomer copolymer (A1) is preferably modified with a silane coupling agent. In such a case, the adhesiveness of solar cell encapsulants to be obtained can be further improved.
  • the silane coupling agent in the ethylene-polar monomer copolymer (A1) according to the present embodiment preferably contains one or more kinds selected from a silane coupling agent having a polymerizable group, a silane coupling agent having an amino group, and a silane coupling agent having an epoxy group.
  • the amount of the silane coupling agent that can be contained is usually equal to or less than 5 parts by mass and preferably 0.02 to 4 parts by mass with respect to 100 parts by mass of the ethylene-polar monomer copolymer (A1).
  • the silane coupling agent is contained within the above-described range, the adhesiveness of solar cell encapsulants to be obtained can be further improved.
  • the modification of the silane coupling agent into the ethylene-polar monomer copolymer (A1) can be performed by, for example, the same method as for the modification of the silane coupling agent into the epoxy group-containing ethylene-based copolymer (A2) to be described below.
  • the modification of the silane coupling agent into the ethylene-polar monomer copolymer (A1) and the modification of the silane coupling agent into the epoxy group-containing ethylene-based copolymer (A2) may be performed at the same time.
  • the amount of a polymerization initiator that is used for the modification and can be contained is, for example, 0.1 to 5 parts by mass and preferably 0.2 to 3 parts by mass with respect to a total of 100 parts by mass of the ethylene-polar monomer copolymer (A1) and the epoxy group-containing ethylene-based copolymer (A2).
  • the amount of the silane coupling agent that can be contained is, for example, equal to or less than 5 parts by mass and preferably 0.02 to 3 parts by mass with respect to a total of 100 parts by mass of the ethylene-polar monomer copolymer (A1) and the epoxy group-containing ethylene-based copolymer (A2).
  • the silane coupling agent is contained within the above-described range, the adhesiveness of solar cell encapsulants to be obtained can be further improved.
  • the content of the silane coupling agent is preferably equal to or more than 0.01% by mass and equal to or less than 2% by mass and more preferably equal to or more than 0.05% by mass and equal to or less than 1.0% by mass.
  • the content of the silane coupling agent also includes the silane coupling agent that has been grafted to the ethylene-polar monomer copolymer (A1) and the epoxy group-containing ethylene-based copolymer (A2).
  • the content of the ethylene-polar monomer copolymer (A1) in the resin composition (P) according to the present embodiment is preferably equal to or more than 1% by mass and equal to or less than 10% by mass, more preferably equal to or more than 2% by mass and equal to or less than 8% by mass, and particularly preferably equal to or more than 3% by mass and equal to or less than 7% by mass.
  • the content of the ethylene-polar monomer copolymer (A1) is within the above-described range, the performance balance of the transparency, adhesiveness, moisture resistance, insulating properties, flexibility, heat resistance, and processability of solar cell encapsulants to be obtained can be further improved.
  • Examples of the epoxy group-containing ethylene-based copolymer (A2) include glycidyl group-containing ethylene-based copolymers.
  • Examples of the glycidyl group-containing ethylene-based copolymers include at least one kind selected from an ethylene-glycidyl (meth)acrylate copolymer, an ethylene-glycidyl (meth)acrylate-vinyl acetate copolymer, an ethylene-glycidyl (meth)acrylate-(meth)acrylate ester copolymer, and the like.
  • the epoxy group-containing ethylene-based copolymer (A2) can be obtained by copolymerizing a polymerizable group such as glycidyl (meth)acrylate, glycidyl vinyl ether, 1,2-epoxy-4-vinylcyclohexane, or 3,4-epoxycyclohexylmethyl methacrylate and a monomer having an epoxy group with ethylene.
  • a polymerizable group such as glycidyl (meth)acrylate, glycidyl vinyl ether, 1,2-epoxy-4-vinylcyclohexane, or 3,4-epoxycyclohexylmethyl methacrylate
  • an epoxy group may be introduced by the graft polymerization of a monomer having an epoxy group into an ethylene-based copolymer.
  • the content proportion of a constituent unit derived from a monomer containing an epoxy group in the epoxy group-containing ethylene-based copolymer (A2) is preferably equal to or more than 2% by mass and equal to or less than 30% by mass, more preferably equal to or more than 3% by mass and equal to or less than 25% by mass, and even more preferably equal to or more than 3% by mass and equal to or less than 15% by mass.
  • the content proportion of the constituent unit derived from the monomer containing an epoxy group is equal to or more than the lower limit value, the interlayer adhesiveness of solar cell encapsulants to be obtained to solar cell modules become more favorable, and the transparency and flexibility of the solar cell encapsulants also become more favorable.
  • the content proportion is equal to or less than the upper limit value, the processability of the solar cell encapsulants improves.
  • Glycidyl (meth)acrylate represents one or both of glycidyl methacrylate and glycidyl acrylate.
  • the "ethylene-based copolymer” in the epoxy group-containing ethylene-based copolymer (A2) means that a constituent unit derived from ethylene is the main component.
  • the "main component” mentioned herein means that the content of the "ethylene-derived constituent unit” is the largest among all of the constituent units.
  • the fraction of the constituent unit derived from ethylene is larger than the fraction of a constituent unit derived from glycidyl (meth)acrylate or a constituent unit derived from vinyl acetate.
  • the fraction of the ethylene-derived constituent unit in the epoxy group-containing ethylene-based copolymer (A2) is preferably equal to or more than 50% by mass, more preferably equal to or more than 65% by mass, even more preferably equal to or more than 70% by mass, and particularly preferably equal to or more than 75% by mass and is preferably equal to or less than 95% by mass, more preferably equal to or less than 90% by mass, and even more preferably equal to or less than 85% by mass.
  • the epoxy group-containing ethylene-based copolymer may further contain a different monomer unit other than ethylene and the monomers having an epoxy group.
  • Examples of the different monomer include vinyl esters such as vinyl acetate and vinyl propionate; unsaturated carboxylic acid esters such as acrylic acid ester, methacrylic acid ester, ethacrylic acid ester, crotonic acid ester, fumaric acid ester, maleic acid ester, maleic anhydride ester, itaconic acid ester, and itaconic acid anhydride ester; and the like.
  • vinyl esters such as vinyl acetate and vinyl propionate
  • unsaturated carboxylic acid esters such as acrylic acid ester, methacrylic acid ester, ethacrylic acid ester, crotonic acid ester, fumaric acid ester, maleic acid ester, maleic anhydride ester, itaconic acid ester, and itaconic acid anhydride ester
  • unsaturated carboxylic acid esters such as acrylic acid ester, methacrylic acid ester, ethacrylic acid ester, crotonic acid ester, fumaric acid
  • Examples of an ester group include alkyl ester groups having 1 to 12 carbon atoms, and more specifically, alkyl ester groups such as methyl ester, ethyl ester, n-propyl ester, isopropyl ester, n-butyl ester, isobutyl ester, secondary butyl ester, 2-ethylhexyl ester, and isooctyl ester can be exemplified.
  • At least one kind selected from vinyl acetate and (meth)acrylic acid ester is preferable.
  • copolymers including the constituent unit derived from ethylene and the constituent unit derived from glycidyl (meth) acrylate
  • copolymers further containing, in addition to these two constituent units, at least one of a constituent unit derived from vinyl acetate and a constituent unit derived from (meth)acrylic acid ester are exemplified.
  • the upper limit value of the content proportion of the constituent unit derived from a vinyl ester such as vinyl acetate and the constituent unit derived from an unsaturated carboxylic acid ester such as (meth) acrylic acid ester is preferably equal to or less than 30% by mass and more preferably equal to or less than 20% by mass. In such a case, the moisture permeability of solar cell encapsulants decreases, and the moisture resistance can be further improved.
  • the lower limit value of the content proportion of the constituent unit derived from the vinyl ester such as vinyl acetate and the constituent unit derived from the unsaturated carboxylic acid ester such as (meth) acrylic acid ester is not particularly limited, but is preferably equal to or more than 0.1% by mass, more preferably equal to or more than 0.5% by mass, and even more preferably equal to or more than 1% by mass.
  • the content proportion of the constituent unit derived from the vinyl ester such as vinyl acetate and the constituent unit derived from the unsaturated carboxylic acid ester such as (meth) acrylic acid ester is preferably within a range of 0.1% to 30% by mass, more preferably within a range of 0.5% to 20% by mass, and particularly preferably within a range of 1% to 20% by mass.
  • epoxy group-containing ethylene-based copolymer (A2) one kind of copolymer can be used singly or two or more kinds of copolymers having different copolymerization rates or the like can be used in combination.
  • the content of the epoxy group-containing ethylene-based copolymer (A2) in the resin composition (P) according to the present embodiment is preferably equal to or more than 1% by mass and equal to or less than 10% by mass, more preferably equal to or more than 2% by mass and equal to or less than 8% by mass, and particularly preferably equal to or more than 3% by mass and equal to or less than 7% by mass.
  • the content of the epoxy group-containing ethylene-based copolymer (A2) is within the above-described range, the performance balance of the transparency, adhesiveness, moisture resistance, insulating properties, flexibility, heat resistance, and processability of solar cell encapsulants to be obtained can be further improved.
  • At least a part of the epoxy group-containing ethylene-based copolymer (A2) is preferably modified with a silane coupling agent. In such a case, the adhesiveness of solar cell encapsulants to be obtained can be further improved.
  • the silane coupling agent in the epoxy group-containing ethylene-based copolymer (A2) preferably contains one or more kinds selected from a silane coupling agent having a polymerizable group, a silane coupling agent having an amino group, and a silane coupling agent having an epoxy group.
  • the modification of the silane coupling agent into the epoxy group-containing ethylene-based copolymer (A2) is, for example, a method in which the epoxy group-containing ethylene-based copolymer (A2) and a silane coupling agent having an amino group or an epoxy group are reacted with each other under heating (at, for example, 100°C to 200°C) (modification method 1), a method in which a silane coupling agent having a polymerizable group is graft-polymerized into the epoxy group-containing ethylene-based copolymer (A2) using a polymerization initiator (modification method 2), or the like.
  • the amino group or the epoxy group in the silane coupling agent and a glycidyl group in the epoxy group-containing ethylene-based copolymer (A2) react with each other, whereby the silane coupling agent is introduced into a side chain of the epoxy group-containing ethylene-based copolymer (A2).
  • the silane coupling agent can be manufactured by, for example, melting and kneading the epoxy group-containing ethylene-based copolymer (A2), the silane coupling agent having a polymerizable group, and a radical polymerization initiator using an extruder, a kneader, a Banbury mixer, or the like at a temperature equal to or higher than the melting point of the epoxy group-containing ethylene-based copolymer (A2) and equal to or higher than the decomposition temperature of the radical polymerization initiator. These reactions can also be performed in solutions.
  • polymerization initiator a usually-used polymerization initiator can be used, but an organic peroxide is preferable.
  • organic peroxide a known organic peroxide that can be used as a polymerization initiator can be used, and specific examples thereof include diacyl peroxide compounds, alkyl peroxy ester compounds, peroxydicarbonate compounds, peroxycarbonate compounds, peroxyketal compounds, dialkyl peroxide compounds, hydroperoxide compounds, ketone peroxide compounds, and the like.
  • dialkyl peroxide compounds are preferable, and 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 1,3-di(2-t-butylperoxyisopropyl)benzene, di-t-butyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3 are more preferable.
  • silane coupling agent having a polymerizable group examples include vinyltrimethoxysilane, vinyltriethoxysilane,
  • silane coupling agent having an amino group examples include hydrochlorides of
  • silane coupling agent having an epoxy group examples include 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,
  • the melt mass flow rate (MFR) of the epoxy group-containing ethylene-based copolymer (A2) as measured according to JIS K 7210:1999 under conditions of 190°C and a load of 2160 g is preferably equal to or more than 0.1 g/10 minutes and equal to or less than 50 g/10 minutes, more preferably equal to or more than 0.5 g/10 minutes and equal to or less than 30 g/10 minutes, and even more preferably equal to or more than 1 g/10 minutes and equal to or less than 20 g/10 minutes.
  • the amount of the polymerization initiator that is used for the modification and can be contained is usually 0.1 to 5 parts by mass and preferably 0.5 to 3 parts by mass with respect to 100 parts by mass of the epoxy group-containing ethylene-based copolymer (A2).
  • the amount of the silane coupling agent that can be contained is usually equal to or less than 5 parts by mass and preferably 0.02 to 4 parts by mass with respect to 100 parts by mass of the epoxy group-containing ethylene-based copolymer (A2).
  • the silane coupling agent is contained within the above-described range, the adhesiveness of solar cell encapsulants to be obtained can be further improved.
  • the mass ratio of the content of the ethylene-polar monomer copolymer (A1) to the content of the epoxy group-containing ethylene-based copolymer (A2) in the resin composition (P) is preferably equal to or more than 0.1 and equal to or less than 10 and more preferably equal to or more than 0.5 and equal to or less than 5. In such a case, it is possible to further improve the balance of the adhesiveness, flexibility, mechanical properties, heat resistance, handleability, processability, and the like of solar cell encapsulants to be obtained.
  • the content proportion of a constituent unit derived from an ⁇ -olefin is preferably equal to or more than 5 mol%.
  • the content proportion is more preferably equal to or more than 10 mol%.
  • the upper limit is less than 50 mol%, preferably equal to or less than 40 mol%, and particularly preferably equal to or less than 30 mol%.
  • an ⁇ -olefin having 3 to 20 carbon atoms is preferable.
  • 3 to 20 carbon atoms include linear ⁇ -olefins such as propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nanodecene, and 1-eicosene; branched ⁇ -olefins such as 3-methyl-1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 2-ethyl-1-hexene, and 2,2,4-trimethyl-1-pentene; and the like, and these ⁇ -olefin
  • the number of carbon atoms in the ⁇ -olefin is preferably 3 to 10 and more preferably 3 to 8 from the viewpoint of versatility (cost, mass productivity, or easiness in procurement).
  • the ethylene- ⁇ -olefin copolymer is preferably an ethylene-propylene copolymer, an ethylene-1-butene copolymer, an ethylene-4-methyl-1-pentene copolymer, an ethylene-1-hexene copolymer, or an ethylene-1-octene copolymer, and, in all of the ethylene- ⁇ -olefin copolymers, the content of an ethylene-derived constituent unit is equal to or more than 50 mol%.
  • the ethylene- ⁇ -olefin copolymers may be used singly or two or more kinds thereof may be used in combination.
  • the ethylene- ⁇ -olefin copolymer can be manufactured by, for example, a slurry polymerization method, a solution polymerization method, a bulk polymerization method, a gas phase polymerization method or the like in which a metallocene-based catalyst is used.
  • the density of the ethylene- ⁇ -olefin copolymer as measured according to JIS K 7112: 1999 is preferably equal to or more than 850 kg/m 3 , more preferably equal to or more than 860 kg/m 3 , and particularly preferably equal to or more than 870 kg/m 3 .
  • the density of the ethylene- ⁇ -olefin copolymer is equal to or more than the above-described lower limit value, the heat resistance becomes more favorable.
  • the density of the ethylene- ⁇ -olefin copolymer as measured according to JIS K 7112: 1999 is preferably equal to or less than 910 kg/m 3 .
  • the density of the ethylene- ⁇ -olefin copolymer is equal to or less than the above-described upper limit value, the balance of the adhesiveness, flexibility and transparency of solar cell encapsulants becomes more favorable.
  • the content of the ethylene- ⁇ -olefin copolymer (B) in the resin composition (P) according to the present embodiment is preferably equal to or more than 80% by mass, more preferably equal to or more than 84% by mass, and even more preferably equal to or more than 86% by mass.
  • the upper limit of the content of the ethylene- ⁇ -olefin copolymer (B) is not particularly limited, but is, for example, preferably equal to or less than 98% by mass, more preferably equal to or less than 96% by mass, and even more preferably equal to or less than 94% by mass.
  • the content of the ethylene- ⁇ -olefin copolymer (B) is within the above-described range, the performance balance of the transparency, adhesiveness, moisture resistance, insulating properties, flexibility, heat resistance, and processability of solar cell encapsulants to be obtained can be further improved.
  • metal inactivating agent (C) As the metal inactivating agent (C) according to the present embodiment, an agent well known as a compound that suppresses metal damage of thermoplastic resins can be used. Two or more kinds of metal inactivating agents may be jointly used.
  • Examples of the metal inactivating agent (C) according to the present embodiment include a compound having a hydrazine skeleton, a compound having a triazole skeleton, and the like.
  • Examples of the compound having a hydrazine skeleton include decamethylene dicarboxyl-disalicyloyl hydrazide, 2',3-bis[3-[3,5-di-tert-butyl-4-hydroxyphenyl] propionyl] propionohydrazide, isophthalic acid bis(2-phenoxypropionylhydrazide) .
  • Examples of the compound having a triazole skeleton include 3-(N-salicyloyl) amino-1,2,4-triazole.
  • decamethylene dicarboxyl-disalicyloyl hydrazide is put into commercially available under the product name of ADEKA STAB CDA-6S manufactured by ADEKA Corporation, and 2',3-bis[3-[3,5-di-tert-butyl-4-hydroxyphenyl] propionyl] propionohydrazide is put into commercially available under the product name of IRGANOX MD1024 manufactured by Ciba Specialty Chemicals Co., Ltd. (currently BASF Japan Ltd.).
  • 3-(N-salicyloyl) amino-1,2,4-triazole is put into commercially available under the product name of ADEKA STAB CDA-1 and CDA-1M manufactured by ADEKA Corporation.
  • the content of the metal inactivating agent (C) in the resin composition (P) is preferably equal to or more than 0.05 parts by mass and more preferably equal to or more than 0.10 parts by mass.
  • the content of the metal inactivating agent (C) is equal to or more than the above-described lower limit value, it is possible to further improve the yellowing resistance of solar cell encapsulants.
  • the upper limit of the content of the metal inactivating agent (C) is not particularly limited, but is, for example, equal to or less than 5.0 parts by mass, preferably equal to or less than 3.0 parts by mass, and more preferably equal to or less than 1.0 part by mass.
  • components other than the ethylene-polar monomer copolymer (A1), the epoxy group-containing ethylene-based copolymer (A2), the ethylene- ⁇ -olefin copolymer (B), and the metal inactivating agent (C) can be contained to an extent that the object of the present invention is not impaired.
  • the other components are not particularly limited, and examples thereof include a plasticizer, an oxidation inhibitor, an ultraviolet absorber, a wavelength conversion agent, an antistatic agent, a surfactant, a colorant, a lightfastness stabilizer, a foaming agent, a lubricating agent, a crystal nucleating agent, a crystallization accelerator, a crystallization retardant, a catalyst deactivator, a heat ray absorber, a heat ray reflecting agent, a heat dissipating agent, a thermoplastic resin, a thermosetting resin, an inorganic filler, an organic filler, an impact resistance improving agent, a slip agent, a cross-linking agent, a cross-linking aid, a tackifier, a processing aid, a mold release agent, a hydrolysis inhibitor, a heat-resistant stabilizer, an antiblocking agent, an antifogging agent, a flame retardant, a flame retardant aid, a light diffusing agent, an antibacterial agent, an antifungal
  • a solar cell encapsulant according to the present embodiment includes a layer formed of the resin composition (P) according to the present embodiment.
  • the solar cell encapsulant according to the present embodiment may have a single-layer constitution or may have a multilayer constitution of two or more layers.
  • the solar cell encapsulant according to the present embodiment may be a film having a single-layer constitution made of a layer formed of the resin composition (P) according to the present embodiment, may be a film having a multilayer constitution made up of two or more layers formed of the resin composition (P) according to the present embodiment, or may be a film having a multilayer constitution having at least one layer formed of the resin composition (P) according to the present embodiment and at least one layer other than the layer formed of the resin composition (P) according to the present embodiment.
  • a layer formed of the solar cell encapsulant according to the present embodiment is also referred to as an encapsulated resin layer.
  • the encapsulated resin layer may have a single-layer constitution or a multilayer constitution of two or more layers.
  • Examples of the layer other than the layer formed of the resin composition (P) according to the present embodiment include layers formed of a resin composition containing at least one kind of ethylene-based copolymer selected from an ethylene-vinyl ester copolymer, an ethylene- ⁇ -olefin copolymer, and an ionomer of an ethylene-unsaturated carboxylic acid-based copolymer.
  • ethylene-vinyl ester copolymer and the ethylene- ⁇ -olefin copolymer for example, the above-described ethylene-vinyl ester copolymer and ethylene- ⁇ -olefin copolymer can be used.
  • the ionomer of the ethylene-unsaturated carboxylic acid-based copolymer is a resin in which at least a part of carboxyl groups in a polymer obtained by copolymerizing ethylene and at least one kind of unsaturated carboxylic acid have been neutralized with metal ions .
  • a copolymer containing ethylene and an unsaturated carboxylic acid a copolymer containing ethylene, an unsaturated carboxylic acid, and an unsaturated carboxylic acid ester, and the like can be exemplified.
  • the unsaturated carboxylic acid that constitutes the ionomer of the ethylene-unsaturated carboxylic acid-based copolymer include acrylic acid, methacrylic acid, 2-ethylacrylic acid, crotonic acid, maleic acid, fumaric acid, itaconic acid, maleic anhydride, fumaric anhydride, itaconic anhydride, monomethyl maleate, monoethyl maleate, and the like.
  • the ethylene-unsaturated carboxylic acid-based copolymer is particularly preferably an ethylene- (meth) acrylic acid copolymer and an ethylene- (meth) acrylic acid- (meth) acrylic acid ester copolymer.
  • Examples of the metal ions that constitute the ionomer of the ethylene-unsaturated carboxylic acid-based copolymer according to the present embodiment include one or more kinds selected from the group consisting of a lithium ion, a potassium ion, a sodium ion, a silver ion, a copper ion, a calcium ion, a magnesium ion, a zinc ion, an aluminum ion, a barium ion, a beryllium ion, a strontium ion, a tin ion, a lead ion, an iron ion, a cobalt ion, and a nickel ion.
  • the layer other than the layer composed of the resin composition (P) according to the present embodiment is preferably a resin sheet formed of an ethylene-vinyl acetate copolymer (EVA), an ethylene- ⁇ -olefin copolymer, and an ionomer of an ethylene-unsaturated carboxylic acid-based copolymer.
  • EVA ethylene-vinyl acetate copolymer
  • ethylene- ⁇ -olefin copolymer ethylene- ⁇ -olefin copolymer
  • an ionomer of an ethylene-unsaturated carboxylic acid-based copolymer for example, a layer known as a solar cell encapsulant can be used.
  • the layer formed of the resin composition (P) according to the present embodiment is used on a side where the solar cell encapsulant comes into contact with a metal material. This makes it possible to more effectively suppress the yellowing of the solar cell encapsulant.
  • the thickness of the solar cell encapsulant according to the present embodiment is, for example, equal to or more than 0.001 mm and equal to or less than 10 mm, preferably equal to or more than 0.01 mm and equal to or less than 5 mm, and more preferably equal to or more than 0.05 mm and equal to or less than 2 mm.
  • the thickness of the solar cell encapsulant is equal to or more than the lower limit value, it is possible to further improve the mechanical strength or insulating properties of the solar cell encapsulant.
  • the thickness of the solar cell encapsulant is equal to or less than the upper limit value, it is possible to further improve the transparency of solar cell encapsulants to be obtained.
  • the solar cell encapsulant according to the present embodiment has a laminated structure in which a layer formed of the resin composition (P) and a layer formed of a resin composition containing at least one kind of ethylene-based copolymer selected from an ethylene-vinyl ester copolymer, an ethylene- ⁇ -olefin copolymer, and an ionomer of an ethylene-unsaturated carboxylic acid-based copolymer are laminated
  • the thickness of the layer formed of the resin composition (P) is, for example, equal to or more than 10 ⁇ m and equal to or less than 900 ⁇ m.
  • a manufacturing method of a solar cell encapsulant according to the present embodiment is not particularly limited, and a conventionally known manufacturing method can be used.
  • the manufacturing method of a solar cell encapsulant according to the present embodiment for example, a press molding method, an extrusion molding method, a T-die molding method, an injection molding method, a compression molding method, a cast molding method, a calender molding method, an inflation molding method, and the like can be used.
  • the extrusion molding method is preferable. That is, the solar cell encapsulant according to the present embodiment can be obtained by, for example, a manufacturing method including a step of extruding the resin composition (P) according to the present embodiment into a sheet shape.
  • Fig. 1 is a cross-sectional view schematically illustrating an example of the structure of a solar cell module 1 according to the embodiment of the present invention.
  • the solar cell module 1 according to the present embodiment includes, for example, solar cell elements 3 and an encapsulated resin layer 5 formed of the solar cell encapsulant according to the present embodiment that encapsulates the solar cell elements 3.
  • the solar cell module 1 according to the present embodiment may further include a substrate 2 on which sunlight is incident, a protective material 4, or the like as necessary. There will be cases where the substrate 2 on which sunlight is incident is simply referred to as the substrate 2.
  • the solar cell elements 3 are sandwiched by the encapsulated resin layer 5, and these are further sandwiched by the substrate 2 and the protective material 4 to form a laminate.
  • the solar cell module 1 can be produced by heating and pressurizing the laminate to attach the individual members.
  • a solar cell module 1 various types of solar cell modules may be exemplified. Examples thereof include a solar cell module having a constitution in which a solar cell element is sandwiched by encapsulants from both sides by laminating a substrate, the encapsulant, the solar cell element, the encapsulant, and a protective material in this order; a solar cell module constituted by laminating a solar cell element formed in advance on the surface of a substrate such as glass in the order of the substrate, the solar cell element, a encapsulant, and a protective material; a solar cell module having a constitution in which a encapsulant and a protective material are formed on a solar cell element formed on the inner peripheral surface of a substrate, for example, an amorphous solar cell element produced on a fluororesin-based sheet by sputtering; and the like.
  • the protective material 4 is provided on a side of the solar cell module 1 opposite to the substrate 2, that is, in the lower part, and is thus referred to as the lower protective material or rear surface protective material in some cases.
  • various solar cell elements such as silicon-based solar cell elements containing single crystal silicon, polycrystalline silicon, amorphous silicon, or the like; Group III-V or Group II-VI compound semiconductor-based solar cell elements containing gallium-arsenic, copper-indium-selenium, copper-indium-gallium-selenium, cadmium-tellurium, or the like; and heterojunction-type solar cell elements of amorphous silicon and single crystal silicon can be used.
  • a plurality of the solar cell elements 3 are electrically connected in series through interconnectors 6.
  • the solar cell module 1 usually includes a metal material provided adjacent to the encapsulated resin layer 5.
  • a layer formed of the resin composition (P) is in contact with at least a part of the metal material.
  • the layer formed of the resin composition (P) is positioned on at least one surface of the encapsulated resin layer 5, and the surface of the encapsulated resin layer 5 on the side of the layer formed of the resin composition (P) is in contact with at least a part of the metal material, for example, one surface of the metal material. Since the layer formed of the resin composition (P) according to the present embodiment is excellent in terms of yellowing resistance, it is possible to suppress yellowing even in a case where the encapsulated resin layer 5 is in contact with the metal material.
  • Examples of the metal material include a bus bar electrode, an interconnector, a finger electrode, and the like. Such metal materials are usually wiring, electrodes, and the like.
  • the bus bar electrode, the interconnector, and the finger electrode are used in modules to join solar cell elements or to collect generated electricity.
  • the metal material contains, for example, at least one metal selected from copper, tin, lead, iron, bismuth, aluminum, and silver.
  • the solar cell encapsulant according to the present embodiment is particularly effective for solar cell modules in which the metal material contains copper.
  • Examples of the substrate 2 that constitutes the solar cell module 1 according to the present embodiment include glass, an acrylic resin, a polycarbonate, a polyester, a fluorine-containing resin, and the like.
  • the protective material 4 (lower protective material) is a single substance of metal, various inorganic materials, various thermoplastic resin films, or the like or a multilayer sheet thereof, and examples thereof include single-layer or multilayer sheets made of metal such as tin, aluminum, or stainless steel; an inorganic material such as glass; a thermoplastic resin film of a polyester, an inorganic vapor deposited polyester, a fluorine-containing resin, a polyolefin, or the like.
  • the solar cell encapsulant according to the present embodiment exhibits favorable adhesiveness to the substrate 2 or the protective material 4.
  • the manufacturing method of the solar cell module 1 is not particularly limited, and examples thereof include the following method.
  • a plurality of the solar cell elements 3 electrically connected using the interconnectors 6 are sandwiched by the solar cell encapsulants, and these solar cell encapsulants are further sandwiched by the substrate 2 and the protective material 4, thereby producing a laminate.
  • the laminate is heated and pressurized to attach the individual members, thereby obtaining the solar cell module 1.
  • Laminates obtained in examples and comparative examples were left to stand at 140°C for 144 hours or 288 hours.
  • the central parts of the laminates were visually observed, and the yellowing resistance was evaluated based on the following criteria.
  • ethylene-glycidyl methacrylate-vinyl acetate copolymer (EGMAVA, manufactured by Sumitomo Chemical Co., Ltd., BONDFAST 7B, ethylene content: 83% by mass, glycidyl methacrylate content: 12% by mass, vinyl acetate content: 5% by mass, MFR (190°C, load of 2160 g): 7 g/10 minutes), 49 parts by mass of an ethylene-vinyl acetate copolymer (vinyl acetate content: 19% by mass, MFR (190°C, load of 2160 g): 47 g/10 minutes), 1.5 parts by mass of 3-methacryloxypropyltrimethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., trade name "KBM503”), and 0.5 parts by mass of 2,5-dimethyl-2,5-di(t-butylperoxy)hexane (manufactured by
  • Ethylene- ⁇ -olefin copolymer (B-1) Ethylene- ⁇ -olefin copolymer (manufactured by Mitsui Chemicals, Inc., TAFMER A-4090S, MFR: 3.6 g/10 minutes, density: 893 kg/m 3 )
  • Examples 1 to 4 and Comparative Example 3 Individual components were melted and kneaded at 175°C in formulation proportions shown in Table 1 to obtain individual resin compositions. Next, the obtained resin compositions were press-molded with a heat press machine to produce sheet-shaped solar cell encapsulants having a thickness of 0.1 mm.
  • TPT back sheet (BEC-301, manufactured by Hangzhou First PV MATERIAL Co., Ltd) cut out to 25 mm ⁇ 25 mm, and each of the sheet-shaped solar cell encapsulants obtained above (second layer), the first layer sheet, and a PET (polyethylene terephthalate) sheet were overlaid in this order in a constitution shown in Table 1 on the copper wires, thereby manufacturing a laminated sheet.
  • the obtained laminated sheets were heated to 150°C for 3 minutes under a vacuum and then heated at 150°C for 5 minutes under pressure to produce individual laminates.
  • the units (phr) of the amounts of various additives formulated indicate parts by mass when the total of the resin components was defined as 100 parts by mass.
  • Copper wires having a diameter of 0.4 mm were bundled and arranged on a TPT back sheet (BEC-301, manufactured by Hangzhou First PV MATERIAL Co., Ltd) cut out to 25 mm ⁇ 25 mm, and the first layer sheet and a PET (polyethylene terephthalate) sheet were overlaid in this order in a constitution shown in Table 1 on the copper wires, thereby manufacturing a laminated sheet.
  • the obtained laminated sheets were heated to 150°C for 3 minutes under a vacuum and then heated at 150°C for 5 minutes under pressure to produce individual laminates.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
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  • Health & Medical Sciences (AREA)
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  • Electromagnetism (AREA)
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  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Photovoltaic Devices (AREA)
EP20900900.0A 2019-12-16 2020-12-09 Composition de résine pour encapsulation de cellule solaire, matériau d'encapsulation de cellule solaire ainsi que procédé de fabrication de celui-ci, et module de cellules solaires Pending EP4079520A4 (fr)

Applications Claiming Priority (2)

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JP2019226268 2019-12-16
PCT/JP2020/045805 WO2021125004A1 (fr) 2019-12-16 2020-12-09 Composition de résine pour encapsulation de cellule solaire, matériau d'encapsulation de cellule solaire ainsi que procédé de fabrication de celui-ci, et module de cellules solaires

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EP4079520A1 true EP4079520A1 (fr) 2022-10-26
EP4079520A4 EP4079520A4 (fr) 2024-01-03

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EP (1) EP4079520A4 (fr)
JP (1) JP7410179B2 (fr)
KR (1) KR20220115991A (fr)
CN (1) CN114845872A (fr)
BR (1) BR112022011794A2 (fr)
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WO2011014777A1 (fr) * 2009-07-31 2011-02-03 E. I. Du Pont De Nemours And Company Agents d’encapsulation réticulables pour cellules photovoltaïques
WO2011059009A1 (fr) 2009-11-13 2011-05-19 三井・デュポンポリケミカル株式会社 Module de pile solaire à silicium amorphe
US20120255610A1 (en) 2011-04-07 2012-10-11 Bokria Jayesh Ghewarchand Encapsulant for Terrestrial Photovoltaic Modules
JP2014107323A (ja) 2012-11-26 2014-06-09 Sekisui Film Kk 太陽電池用封止膜
JP6914841B2 (ja) 2015-09-29 2021-08-04 三井・ダウポリケミカル株式会社 太陽電池封止材用多層シート、太陽電池封止材用多層シートの製造方法および太陽電池モジュール
CN108138000B (zh) * 2015-09-30 2021-04-16 三井—杜邦聚合化学株式会社 绝缘性多层片材及太阳能电池模块
JP2018174202A (ja) 2017-03-31 2018-11-08 株式会社ブリヂストン 太陽電池用封止材及びこれを用いた太陽電池モジュール

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CN114845872A (zh) 2022-08-02
JP7410179B2 (ja) 2024-01-09
EP4079520A4 (fr) 2024-01-03
JPWO2021125004A1 (fr) 2021-06-24
BR112022011794A2 (pt) 2022-08-30
TW202132453A (zh) 2021-09-01
US20230006081A1 (en) 2023-01-05
WO2021125004A1 (fr) 2021-06-24

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